F646_CompleteSample

The Market for Gas Turbine Electrical Power Generation

Product Code #F646 A Special Focused Market Segment Analysis by:

Industrial & Marine Turbine Forecast - Gas & Steam Turbines

©2009 September 2009

Analysis 1 The Market for Gas Turbine Electrical Power Generation

2009-2018 Table of Contents

Executive Summary .................................................................................................................................................2 Introduction................................................................................................................................................................3

Format and Methodology........................................................................................................................................4

Trends and Competitive Environment ................................................................................................................6

Manufacturers Review .............................................................................................................................................7 Market Statistics .....................................................................................................................................................15

Figure 1 - Gas Turbine Electrical Power Generation Power Class Unit Comparison 2009 - 2018 (Bar Graph).........................................................16

Figure 2 - Gas Turbine Electrical Power Generation Power Class Unit Comparison 2009 - 2018 (Pie Chart) ..........................................................16

Figure 3 - Gas Turbine Electrical Power Generation Power Class Value Comparison 2009 - 2018 (Bar Graph) ......................................................17

Figure 4 - Gas Turbine Electrical Power Generation Power Class Value Comparison 2009 - 2018 (Pie Chart) ........................................................17

Table 1 - The Market for Gas Turbine Electrical Power Generation Unit Production by Headquarters/Company/Program 2009 - 2018 ................................................20

Table 2 - The Market for Gas Turbine Electrical Power Generation Value Statistics by Headquarters/Company/Program 2009 - 2018 .................................................27

Figure 5 - Gas Turbine Electrical Power Generation Unit Production 2009 - 2018 (Bar Graph) ...............................................................................34

Figure 6 - Gas Turbine Electrical Power Generation Value of Production 2009 - 2018 (Bar Graph).........................................................................34

Table 3 - The Market for Gas Turbine Electrical Power Generation Unit Production % Market Share by Headquarters/Company 2009 - 2018 ....................................35

Table 4 - The Market for Gas Turbine Electrical Power Generation Value Statistics % Market Share by Headquarters/Company 2009 - 2018 .....................................37

Figure 7 - Gas Turbine Electrical Power Generation Unit Production % Market Share by Headquarters 2009 - 2018 (Pie Chart) ...........................39

Figure 8 - Gas Turbine Electrical Power Generation Value Statistics % Market Share by Headquarters 2009 - 2018 (Pie Chart)............................39

Conclusion ...............................................................................................................................................................40 * * *

Product Code F646 The Market for Gas Turbine Electrical Power Generation


PROGRAMS The following reports are included in this section: (Note: a single report may cover several programs.)

Heavy Gas Turbines (11,185 kW and Larger) Alstom GT 8/11/13 Alstom GT24/GT26 GE LM1600 GE LM2500 GE LM6000 GE LMS100 GE Model 5000 GE Model 6000 GE Model 7000 GE Model 9000 General Electric GE-10 Hitachi H-25 Kawasaki L20A Mitsubishi MF-111 Pratt & Whitney Power Systems FT8 Rolls-Royce Industrial Avon Rolls-Royce Industrial RB211 Rolls-Royce Industrial Spey Rolls-Royce Industrial Trent Siemens SGT-400 Siemens SGT-500 Siemens SGT-600/700 Siemens SGT-800 Siemens SGT5-2000/3000/4000 Siemens Westinghouse SGT6-3000/5000/6000 Solar Titan Heavy Industrial & Marine (I&M) Gas Turbines: Design and Development Light Gas Turbines (Up to 11,185 kW) Daihatsu DT Series Dresser-Rand KG2 General Electric GE-5 Kawasaki M1A/M1T Series Kawasaki M7A Kawasaki S1/S2 Series MAN TURBO THM 1200/1300 Mitsui SB5 Optimal Radial Turbine OP16 Pratt & Whitney Power Systems ST6 Pratt & Whitney Power Systems ST18/ST40 Rolls-Royce 501-K Siemens SGT-100



Siemens SGT-200 Siemens SGT-300 Solar Centaur/Taurus Solar Mars Solar Saturn Turbomeca Makila TI Vericor ASE8 Vericor TF/ASE 40/50 Light Industrial & Marine (I&M) Gas Turbines: Design and Development


©2009

Introduction One of the beauties of gas turbine machines is their extreme flexibility. Schools, civic centers and shopping malls are good applications for 200-kilowatt units; entire cities can be powered by 200-megawatt units. Heat recovery units add the ability to cooperate with industry and provide steam for power or processes, or even supply a municipality with district heating/cooling.

Many lobbies and special interests proclaim dubious facts, incomplete pictures and questionable statistics in an attempt to shape public policy. It is time to develop a comprehensive energy policy that strikes a balance, moving toward renewable and sustainable goals without hobbling the horsepower of economic and technological development.

No solitary source will meet all of the world's power requirements, but gas turbines are increasingly being adapted to many schemes to improve the efficiency and reliability of power projects. Renewable fuels show promise, as well as synthetic fuels from coal and biomass; careful consideration of the energy demand for energy investment is required. It makes no sense to process materials through so many steps that it costs more to make them than any value you will ever get out of them. With the energy demand projected in the next decade, there will be room for unprecedented development in all sectors and regions.

When the need becomes critical, new electrical power generation capacity can come from several sources: fossil-fuel-burning machines such as gas turbines (including microturbine machines of under 250 kW) and the new wave of gas engines and diesels; hydroelectric, nuclear, solar, and wind power; waste-to-energy plants (which burn paper/wood, scrap, food waste, and bagasse); and exotic means such as geothermal energy, ocean currents, and fuel cells.

One source of electrical power, which many dismiss for initially appearing to be fiscally unproductive, is conservation. Though it may slow the demand for new machine installations, there is a positive side to concerted conservation efforts in established markets. First, showing concern for overall efficiency, and not simply immediate profit, helps build credibility with the customer. While many original equipment manufacturers (OEMs) are entering into long-term operations and maintenance contracts, they must be realizing that steady, baseloaded machines and unencumbered transmission and distribution lines are favorable in terms of maintenance costs and overall financial performance.

Fuel cells are still considered to be in the demonstration stage despite their immense appeal stemming from their

"relocation" of harmful emissions, but we believe they will be abundant from about 2014. Wind power, while commercially available, is not available everywhere; its overall efficiency is about 50 percent, and it is expensive in the near term on a dollar-per-kilowatt-hour basis. Nuclear power and hydroelectric plants are very expensive and require a long period of hearings, followed by attempts to obtain financing and approvals, and finally, construction. Solar power is very appealing, but shares the drawbacks of wind power – it is not available everywhere, electrical power storage technology is immature and cannot handle the capacity, and it, too, is expensive on a dollar-per-kilowatt-hour basis.

The viable alternatives are few. Above the level of microturbines, whose efficiencies range from 20-28 percent, are what we consider to be true gas turbine machines that range in power output from 200-250 kW at the low end to the super-high-power machines of 350+ MW. Today, gas turbine machines have simple-cycle efficiencies of at least 35 percent, with some approaching 45 percent, while some are advertised as already having a 60 percent efficiency in combined-cycle mode.

What does past performance predict? While gas turbine machines continued to be ordered and fabricated for electrical generation for their usual end uses (continuous duty, standby duty, and peaking duty), the lower- powered gas turbine machines, those up to 3.5-4 MW, have traditionally been employed in standby duty. As we move up the power spectrum, the normal-use shift toward continuous duty becomes more noticeable at the power level of 20-30 MW. At 120-125 MW and larger, virtually all gas turbine machines have been/should be ordered for use in continuous generation duty.

Given the current need for new baseload capacity, as well as for power plant capacity additions, Forecast International believes that the worldwide demand for the latest technology gas turbine-based power plants will result in modest production of the super-large gas turbine machines, those of 180 MW and larger. Production of those machines could grow from 48 machines in 2003 to 150-160 machines per year in the period 2011-2014. Those machines can be expected to be procured by China, North Korea, Vietnam, Indonesia, Thailand, Brazil, and the Middle East.

With combined-cycle installations touching the 60 percent mark for net plant efficiency ratings, we do not believe that gas turbine machines will continue to Continued…

Industrial & Marine Turbine Forecast

GE Model 7000

Orientation Description. Single-shaft, axial-flow, heavy-duty, industrial-design 60-Hz gas turbine machine with a power output (in simple-cycle operation) in the range of 85 to 172 MW, depending on model.

Sponsor. The Model 7000 was privately developed by the prime manufacturer.

Power Class. The approximate power outputs of the current models in the Frame 7 series (for electrical generation) are as follows:

Simple- Cycle Combined-Cycle Model Output Output Model 7001EA 85.4 MW 130.2 MW Model 7001FA 171.7 MW 262.6 MW Model 7001FB 184.4 MW 280.3 MW Model 7001H – 400.0 MW

For the Frame 7EA, GE Energy performance parameters list a mechanical drive model (see Technical Data section, Performance subsection, for unit outputs for electrical generation and mechanical drive).

Status. In production.

Total Produced. At the start of 2008, about 1,450 GE Energy Frame 7 machines of all current production models had been built by GE and its allied firms.

Application. Utility and industrial power generation installations, including cogeneration and combined-cycle plants and mechanical load drive duty.

Price Range. The prices (in 2008 U.S. dollars) of Frame 7 machines are as follows:

Simple-Cycle Combined-Cycle Model Plant Price Plant Price Model 7001EA $18 -$20 million $76-$78 million Model 7001FA $30 -$32 million $131-$133 million Model 7001FB $34 -$36 million $138-$140 million Model 7001H – $176-$178 million For electrical generation (simple-cycle), the genset price covers a single-fuel skid-mounted gas turbine, electric generator, air intake with basic filter and silencer, exhaust stack, basic starter and controls, and conventional combustion system.

For mechanical drive, the prices cover a gas-fired gas turbine (without driven equipment) with gearbox, skid, enclosure, inlet and exhaust ducts and exhaust silencer; basic turbine controls; fire protection; starting systems; and conventional combustion system.

For combined-cycle plants, the prices cover a basic gas-fired combined-cycle plant having a gas turbine (usually a DLN-equipped machine), unfired multi-pressure heat recovery steam generator (HRSG) without bypass stack, multi-pressure condensing steam turbine, electric generator, step-up transformer, water-cooled heat rejection equipment, standard controls, starting system, and plant auxiliaries.

The Frame 7EA’s 2008 package price for mechanical drive duty is estimated at $15.5-$16.5 million.

Outlook Production activity currently increasing, as power

installers are maintaining a cautious order pattern

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Uni

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Unit Production Forecast 2008-2017

Units 43 61 75 87 89 92 88 90 85 83

2008 2009 2010 2011 2012 2013 2014 2015 2016 2017

STAG-cogen packages are particularly attractive for U.S. customers

Model 7FB and 7H production to rise noticeably in the decade

7FA projected to remain the most popular model in the Frame 7 family, especially in the U.S.

© 20 08 December 2008

Page 2 Industrial & Marine Turbine Forecast

GE Model 7000 Competition. The 60-Hz GE Energy Frame 7 machine faces competition from gas turbine machines built by Alstom, Mitsubishi, and Siemens Westing-house. At the high end of the power spectrum, the

60-Hz Frame 7H in combined-cycle duty competes against packages from Alstom, Mitsubishi and Siemens Westinghouse W501F.

Contractors Prime GE Energy http://www.gepower.com, 4200 Wildwood Pkwy, Atlanta, GA 30339 United States,

Tel: + 1 (770) 859-6000, Fax: + 1 (678) 844-6690, Prime

Hitachi Ltd http://www.hitachi.com, 6-6 Marunouchi 1-chome, Chiyoda-ku, Tokyo, 101-8280 Japan, Tel: + 81 3 3258 1111, Fax: + 81 3 3258 2507, Licensee

Toshiba Corp http://www.toshiba.co.jp, 1-1, Shibaura, 1-chome, Minato-ku, Tokyo, 105-8001 Japan, Tel: + 81 3 3457 4511, Fax: + 81 3 34556 1631, Licensee

Subcontractor Howmet Castings, Corporate Machining

http://www.alcoa.com, 145 Price Rd, Winsted Industrial Park, Winsted, CT 06098 United States, Tel: + 1 (860) 379-3314, Fax: + 1 (860) 379-4239 (Blade, Stage 1)

Mee Industries Inc http://www.meefog.com, 204 West Pomona Ave, Monrovia, CA 91016 United States, Tel: + 1 (626) 359-4550, Fax: + 1 (626) 359-4660 (Gas Turbine Cooling Fog System)

Power Systems Manufacturing LLC

http://www.powermfg.com, 1440 W Indiantown Rd, Suite 200, Jupiter, FL 33458-7925 United States, Tel: + 1 (561) 354-1100, Fax: + 1 (561) 354-1199 (Low Emission Combustion Liner)

Powmat Ltd http://www.powmat.com, Northway 10 Technical Bldg, Ballston Lake, NY 12019 United States, Tel: + 1 (518) 877-8518, Fax: + 1 (518) 877-8523 (Soft Clutch)

Sermatech Power Solutions http://www.sermatech.com, 155 S Limerick Rd, Limerick, PA 19468-1699 United States, Tel: + 1 (610) 948-5100, Fax: + 1 (610) 948-1712, Email: [email protected] (TBC Combustor Coating)

Vogt Power International Inc http://www.babcockpower.com, 1000 W Ormsby Ave & 10th St, PO Box 1918, Louisville, KY 40201-1918 United States, Tel: + 1 (502) 634-1511, Fax: + 1 (502) 637-7344 (HRSG - Virginia Power/Chesterfield 7 & 8)

Comprehensive information on Contractors can be found in Forecast International’s “International Contractors” series. For a detailed description, go to www.forecastinternational.com (see Products & Samples/Governments & Industries) or call + 1 (203) 426-0800.

Contractors are invited to submit updated information to Editor, International Contractors, Forecast International, 22 Commerce Road, Newtown, CT 06470, USA; [email protected]

Technical Data Design Features Intake. Air enters radially through an intake plenum and is turned 90 degrees to enter the compressor.

Compressor. A 17-stage, axial-flow compressor provides a pressure ratio of 12.5:1 (7EA) at an exhaust flow of 298 kg/sec. Inlet guide vanes are provided forward of stage one, with no variable stages thereafter. Stators are integral with the compressor casing, which is horizontally split. Rotors are built up from forged discs, which are fastened with through-bolts. Blades are of wide chord design. Rotor speed is 3,600 rpm. Compressor casing is A46 cast iron or A395 ductile cast

iron. Blades and stator vanes are of 12 percent Cr steel and discs are of Ni-Cr-Mo-V steel. MS7001FA is an 18-stage axial unit, with a 15.5:1 compression ratio and exhaust flow of 432 kg/sec. Stages 2-17 are scaled up from the MS7001E. Stage 1 and a zero stage (borrowed from GE aero engine designs) have been redesigned for operation in transonic flow. The MS7001F has extraction provisions at Stage 13.

The MS7001EC compressor has 18 stages and a pressure ratio of 14.2:1. Airflow is 769 lb/sec (349 kg/ sec). High-strength, corrosion-resistant C450 stainless steel blading is used for inlet guide vanes (IGVs) and

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Industrial & Marine Turbine Forecast Page 3

GE Model 7000

© 20 08 December 2008

the first four stages. Stages 4-8 use AISI 403+Cb stainless steel with GECC-1 coating; the remaining blading is of uncoated AISI 403+Cb alloy. Stator 17 and EGV 1-2 are of cast IN718.

Combustor. Cannular, reverse-flow with 10 combustors, fuel nozzles and two igniters. Fuel nozzles are air atomizing for multi-fuel capability. All chambers are interconnected by flame tubes. Liner and transition ducts are of Hastelloy X, with 7F also using HS-188 in the lower portion. Tf is approximately 2,012°F (1,100°C). MS7001F has 14 cannular reverse-flow combustors, each 25 inches (63.5mm) shorter than on the MS7001E. Each of the 14 combustors is fitted with six fuel nozzles. The combustion liners and new transition piece impingement sleeves are coated with a ceramic thermal barrier for elevated temperatures. MS7001F Tf is approximately 2,300°F (1,260°C).

MS7001EC has five circumferentially arranged fuel nozzles.

Turbine. A three-stage, axial-flow turbine with cooled Stage 1-2 blades and vanes drives the machine at its design speed. Turbine casing is made of A395 ductile cast iron; Stage 1-2 blades are of GTD-111. Stage 1 blades of F are DS-cast and use the GE Evendale-developed cooling technique. Stage 3 blades are of

Udimet 500. Stage 1 vanes are FSX414 and discs and shafts are of Cr-Mo-V steel. All three vane stages of the MS7001F are air-cooled. Stages 2-3 have Z tip shrouds. Nozzles on Stages 2-3 are of GTD-222. All three F blade stages are coated. Stage 1 blades have a plasma-spray coating of CoCrAlY; Stage 2 components are coated with CoCrY; Stage 3 airfoils have a high-Cr coating applied using the pack cementation process.

Stage 3 of the MS7001EC is uncooled. All turbine buckets are investment cast GTD 111; Stage 1 is DS, while Stages 2-3 are equiaxed.

Control System. Control and protection functions for automatic start, loading, shutdown, and other phases of operation are handled by the GE triple-redundant SpeedTronic™ Mark V control system. The microcomputer and microprocessor are contained in a separate control console.

Accessories. Accessory equipment is located forward of the intake plenum and driven by an extension of the forward compressor shaft. Starting: diesel engine with a torque converter electric motor; steam or expansion turbine. The 7E/F and 7F are modular in design.

Bearings. The machine is mounted on five bearings: one tilting and two elliptical pad journal bearings, and two tilting pad thrust bearings (active and inactive).

Dimensions. The approximate dimensions and weights of the Frame 7EA (PG7121(EA)) and Frame 7FA (PG7121(FA)) in a packaged power plant configuration (including inlet and exhaust losses and shaft-driven equipment) are as follows:

Metric Units English Units Frame 7EA (PG7121(EA)) Length 40.23 m 132 ft Width 21.64 m 71 ft Height, with exhaust 9.45 m 31 ft Weight, dry, with accessories 485 tonnes 535 tons Frame 7FA (PG7121(FA)) Length 54.86 m 180 ft Width 22.86 m 75 ft Height, with exhaust 9.45 m 31 ft Weight, dry, with accessories 745 tonnes 821 tons Performance. The performance parameters of the MS7001 models for electrical generation (generator drive) are as follows (ISO, dry, natural gas fuel, standard inlet/exhaust pressure drops):

APPLICATION = SIMPLE-CYCLE GENERATION MS7001EA MS7001FA Output 85.4 MW 171.7 MW Heat Rate (LHV) 10,991 kJ/kWh 9,873 kJ/kWh Pressure Ratio 12.6:1 16.0:1 Mass Flow 292 kg/sec 432 kg/sec Exhaust Temperature 537°C 601°C Model Designation PG7121EA PG7241FA


GE Model 7000 APPLICATION = COMBINED-CYCLE GENERATION MS7001EA MS7001FA MS7001FB MS7001H Output 130.2 MW 262.6 MW 280.3 MW 400.0 MW Heat Rate (LHV) 7,175 kJ/kWh 6,424 kJ/kWh 6,276 kJ/kWh 6,000 kJ/kWh Net Plant Efficiency 50.2% 56.0% 57.3% 60.0% GT Number & Type 1x MS7001EA 1x MS7001FA 1x MS7001FB 1x MS7001H The performance parameters of the MS7001EA model for mechanical load drive applications are as follows (ISO conditions, natural gas fuel):

APPLICATION = MECHANICAL LOAD DRIVE English Units Metric Units Output 115,630 shp 86.2 MW Heat Rate (LHV) 9,795 Btu/shp-hr 10,920 kJ/kWh Pressure Ratio 11.9:1 11.9:1 Exhaust Flow 659 lb/sec 299 kg/sec Exhaust Temperature 998°F 537°C Model Designation M7121EA M7121EA GE offers a range of gas turbines that can efficiently be integrated with IGCC plants. The power outputs of the Frame 7 models for IGCC plant applications are as follows:

APPLICATION = IGCC PLANTS GT Model Syngas Power Rating IGCC Model Net Plant Output Power 7EA 90 MW (60 Hz) 107EA 130 MW (60 Hz) 7FA 197 MW (60 Hz) 107FA 280 MW (60 Hz)

Variants/Upgrades Since the inception of the program, GE and its associates/licensees have installed numerous MS7001 models, starting with the MS7001A rated at approximately 48 MW. Major in-production or soon-to-be-available machine models include the following:

MS7001EA. The MS7001EA is the lowest-power-output production model in the Frame 7 series. It currently has a generator drive output of 85.4 MW, and is listed at 115,630 shp (equivalent to 86.2 MW) for mechanical drive duty.

The 7EA for mechanical load drive duty is available as the MS7111EA at 109,370 shp at an efficiency rating of 32.7 percent, and as the MS7121EA at 115,630 shp at an efficiency rating of 33.0 percent. The MS7111EA is priced at approximately $14.6 million, while the MS7121EA is priced at approximately $15.9 million (both in 2007 U.S. dollars).

MS7001FA. The MS7001FA is a more powerful machine in the Model 7000 line; it has a simple-cycle output rate of 171.7 MW and a simple-cycle-duty efficiency rating of 36 percent.

MS7001FB. The MS7001FB is one of the newer machines in the Model 7000 line. While this model is now available only for combined-cycle duty, we estimate that its simple-cycle output rate is 184.4 MW; its output in combined-cycle operation is listed at 280.3 MW, with a net plant efficiency of 57.3 percent. This model has a Tf of 2,500°F (1,371ºC) and a mass flow of 441.3 kg/sec.

MS7001H. The 60-Hz MS7001H, introduced in 1995 along with the 50-Hz MS9001H, produces 400 MW in combined-cycle operation. Its net plant efficiency in that mode is 60 percent. This model has a maximum Tf of 2,600°F (1,430°C).

Program Review Background. The GE MS7001 first emerged on the drawing boards at GE’s Schenectady (New York) facility in 1970. In designing the new MS7000, GE drew heavily on its experience with the earlier MS5001 and MS5002 single- and twin-shaft models. It designed the MS7001 to provide packaged power in the 60-Hz

arena. The MS7001 compressor is directly scaled from the MS5001 and features the same construction, with individual discs joined by through bolts and wide-chord stainless steel blades; the design makes use of a precision-cast, long-shank air-cooled nozzle and Stage 1 blades.

December 2008


GE Model 7000

© 20 08 December 2008

The current Model 7000 machine design incorporates improvements to the compressor, adds cooling to the Stage 2 turbine components, and utilizes new Stage 3 turbine blades. GE has continued to refine the system (at its division located in Evendale, Ohio), emphasizing new high-temperature materials and using a modified combustion system that will increase life under water-injection conditions for NOx control.

As is the case with all GE-designed power generating systems, the Model 7000 is offered in single- or multi-unit packaged power plants in both simple and combined cycle. The MS7001 forms the base of GE’s combined-cycle plant designs, the S-107E (one gas turbine) and the S-207E (two machines). Also on offer is the S-107F, featuring one MS7001F machine. The combined-cycle plants are also referred to as STAG™ plants.

Frame 7 Update Program. GE is offering a Frame 7 update program to customers of the MS7001 machine. Under the program, pre-MS7001E models can be updated to the MS7001E standard by re-engineering the machine’s hot path and incorporating new-technology parts from the 7E. The key component, as used in Chugach Electric’s Beluga #3 turbine-generator set, is the 7E Stage 1 turbine nozzle, which results in a 6 percent increase in the unit’s compressor pressure ratio and a 3 percent thermal efficiency improvement. Three options are available in GE’s Frame 7 update program. Option I utilizes new reduced camber high-flow inlet guide vanes and 7E Stage 1 buckets and nozzles. Owing to increased efficiency, the actual exhaust gas temperature (EGT) decreases under this option. Chugach Electric decided on this option. Option II involves an increase in firing temperature to keep EGTs at pre-update levels. This option is attractive for units installed in heat-recovery applications where EGT changes could affect combined-cycle efficiency. Option III is intended to achieve maximum firing temperature (1,074°C) with the replacement of all hot gas path components with Frame 7E parts. This option increases Frame 7 ratings to approximately 70-MW ISO conditions.

In addition to uprating the Beluga #3 turbine, GE also increased the rating of the generator while upgrading the generator field with Class F insulation and with 18 percent Mn and 18 percent Cr retaining rings. Similar generator uprates are available for all Frame 7 generators.

Early Sales of MS7001. In 1970, the first MS7001A machine, rated at 48 MW, was installed at the Wading River plant of the Long Island Lighting Co. The following year, 30 units were installed. Those first units

remained in production through 1977, when the current design entered production.

During the 1970s, the U.S. utility market was the target of the Model 7000 marketing effort. However, in 1973, the first overseas sale by a manufacturing associate was completed. Hitachi was the builder and, since that time, the Japanese affiliate of GE has sold at least 19 of the heavy gas turbines. In addition, one of the newest additions to the GE associate list, Marubeni Trading Corp, has sold six Frame 7 machines that were produced by other members of the consortium.

Most of the Model 7000 sales have been for the PPP (Packaged Power Plant) series of prime movers. PPPs include the gas turbine-driven equipment, accessories, controls, enclosures, etc. They can be coupled into power blocks for increased flexibility and efficiency. While the U.S. market has dominated the order book for this machine, recent projects in the Middle East, Asia, and South America have nudged the Model 7000 into the export market.

In 1982, GE and Toshiba began an association in the gas turbine field. In 1983, Toshiba USA bought five MS7001Es for a combined-cycle plant, while Saudi Consolidated Electric ordered two Packaged Power Plants for 1984 commercial startup. Finally, Trinidad and Tobago put two gensets into operation in 1985.

MS7001 in Cogeneration. The big news recently has been in the cogeneration market. In 1983, the U.S. Supreme Court upheld the 1978 PURPA regulations and, almost immediately, GE announced the formation of the Cogeneration Department and the huge partnership agreement with Big Three Industries. Big Three and GE own and operate the new cogeneration plant outside Houston, Texas. The multi-unit facility generates power and steam for industry in the Houston area and sells excess power to Houston Power and Light. Other major industrial plants in the area could also use the GE power plants as industry seeks to protect itself from the historical monopoly of the utility industry.

Among the more notable installations of the GE MS7001 is the Taiwan Electric Power station, which has six GE gas turbines in two STAG 307E systems. Together, they provide a thermal efficiency of 45.3 percent on distillate and 44.8 percent on residual fuel oil.

Uprated GE MS7001F Series. GE had long been working on a higher rated Model 7000. The new, completely redesigned model, the MS7001F (Frame 7F), is ISO baseload rated at 150 MW, nearly 80 percent more powerful than the MS7001EA. The


GE Model 7000 new machine has a thermal efficiency of 34.5 percent and a firing temperature of over 1,260°C. In August 1988, GE announced that it had increased the ratings of the Frame 7F machine, basing the new ratings on the unit’s prototype test series results. The output was raised from 141 to 150 MW, and the heat rate was decreased from 10,545 kJ/kWh to 10,425 kJ/kWh. Pressure ratio, turbine speed, and firing temperature remained the same. The improvements were made without a size or weight change.

Perhaps the most striking difference is that the 7F is a cold-end drive machine. The switch to the front-end drive, where the generator is connected to the turbine shaft aft of the compressor, is in line with accepted practice with machines whose power output is 100 MW or greater. This design permits the use of an axial exhaust, making an in-line plant arrangement possible. For combined-cycle applications, this eliminates loss-inducing elbow sections upstream of the boiler. The 7F’s combustor is designed to be compatible with a variety of fuels, including natural gas, fuel oil, and gasified coal. Accessories are designed for separate mounting in any conventional power plant location.

In combined-cycle installations, the steam and gas (STAG) systems featuring MS7001F machines are available in increments of 225 MW (gas turbine power output plus steam turbine power output).

Around the late 1980s, the Virginia Electric and Power Co (VEPCO), Richmond, Virginia, placed a Letter of Intent with GE for the first 7F unit. The power company installed one new machine to replace two retired coal-fired steam sets. The first unit went commercial in June 1990, and during the summer peak it provided 600,000 kWh of power to VEPCO’s grid, with 200 starts; it accumulated 4,000 hours of operation at a reliability rate of 99 percent. The first field inspection of the unit, performed shortly before the 4,000-hour mark, showed some unexpected hardware distress. This was minor in nature, however, and the causes were quickly determined and design changes implemented.

Emissions testing began with an O2 traverse of the exhaust, which showed a uniform distribution. NOx emissions were below the detectable limit, set at 0.5 to 0.25 ppm. Visible emissions were negligible, and particulates were less than the guaranteed value for the site. Proper measurement of unburned hydrocarbon during gas firing was not attainable due to a leaking gas purge valve. (Laboratory data for natural gas, however, show UHCs to be negligible until the firing temperature goes below 1,700°F [926°C], after which point they rise markedly.) Dynamic pressure readings during dry firing and with water injection fell within a broad band with

no significant variations. Combustor liner temperatures were also within acceptable limits.

In June 1988, GE announced that Potomac Electric Power Co had ordered four MS7001F gas turbine generators for its power-generating plant in Dickerson, Maryland. The four machines were installed at the plant as simple-cycle units, providing 560 MW of power to meet the utility’s near-term summer peaking needs. In the late 1990s, heat recovery equipment and steam turbine-generators were added to the gas turbines to meet the utility’s intermediate load requirements. In addition, provisions were made for the future utilization of coal as a baseload fuel through the addition of coal gasification equipment.

In 1990, five 7EAs and four 7Fs were ordered by customers in the state of Florida. Florida Power Corp ordered four 7EAs for its Debary site, the city of Lakeland ordered one 7EA for its Larsen site, and Florida Power & Light ordered four 7Fs for its Martin 3-4 site.

For the most current power outputs and performance parameters, see the Performance section, above.

Frame 7 and PROGEN. The basic power design of the Frame 7F is compatible with a concept GE calls Progressive Generation, or PROGEN, the staged construction of a power plant over a period of years with operation in three modes: simple cycle, combined cycle, and integrated coal gasification.

Low NOx Work. GE, an early developer of dry low NOx (DLN) combustion systems, announced in November 1991 the commercial availability of single-digit DLN combustors for its heavy-duty gas turbine machines. While the DLN combustors are available for new-production machines, they will become available for retrofit packages for older units at a later date.

DLN systems meeting current emissions standards are being shipped on Frame 6 and Frame 7EA machines; advanced systems achieving emission of 9 ppm are being shipped on E and F technology machines.

GE Offers MS7001EA Uprate Packages

GE Energy offers an uprate package for its MS7001EA gas turbine that uses state-of-the-art components to enable firing temperatures to be increased. According to General Electric Power Systems, the improvements can increase power output by up to 6 percent. GE offers four uprate packages to accommodate the wide range of Frame 7 unit configurations: IGV Upgrade to GTD-450-IGV, Turbine Section Upgrade, Compressor Upgrade to EA Compressor, and Exhaust Isotherm

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GE Model 7000

© 20 08 December 2008

Temperature Upgrade to 1,100°F (593°C). Since the uprate options will increase the Tf and output of the unit, emissions will increase. As such, an evaluation of whether to include an emissions abatement system upgrade or retrofit may be required.

Also being uprated are two 7EA gas turbines at Cogen Technologies’ plant in Linden, New Jersey, and an additional eight 7E machines located at the Kern River and Sycamore Cogen facilities in California.

MS7001EA for Mechanical Load Drive. GE Energy Frame 7/7E/7EA gas turbine machines had been ordered for mechanical load drive duty; those machines are produced by GE in the U.S. and GE Oil & Gas in Italy. While most 7EAs date from 1998, five earlier machines were designated MS7001 or MS7001E. In 1993, three Frame 7 machines were engineered by (then) Nuovo Pignone into mechanical drive machines for duty at an LNG facility in Malaysia.

The 7EA for mechanical load drive duty is available in two models: as the MS7111EA at 109,370 shp, with an efficiency of 32.7 percent and a heat rate of 7,790 Btu/shp-hr; and as the MS7121EA at 115,630 shp, with an efficiency of 33.0 percent and a heat rate of 7,720 Btu/shp-hr.

The 7/7E/7EA has been installed for mechanical load drive duty in Australia, Canada, Egypt, Indonesia, Malaysia, Nigeria, Oman, and Qatar.

MS7001G/H. At the Power-Gen Europe 1995 Conference and Exhibition in Amsterdam, GE Power Systems introduced the G and H series gas turbines. While the G machines were said to be able to reach 58 percent net thermal efficiency in combined-cycle operation, the advanced H technology platform would have at least 60 percent net thermal efficiency. The rise from 55 percent to 60 percent is considered dramatic, since an increase of a single percentage point of efficiency can reduce operating costs by $15 million to $20 million over the life of a typical gas-fired, combined-cycle plant in the 400-500 MW range.

G technology gas turbines were said at the time to be planned for use in both simple-cycle and combined-cycle operation, while H technology machines would be offered solely for use in combined-cycle operation.

According to the manufacturer, the H technology is “a platform of combined-cycle technology that integrates the gas turbine, steam turbine, and generator into a seamless system in which each component is optimized for the highest level of performance. The centerpiece of this new technology is an advanced closed-loop steam

cooling system in the gas turbine, which permits higher firing temperatures while retaining combustion temperatures at levels consistent with low emissions. Unlike aircraft engines, which only have air for cooling, a combined-cycle system has a ready steam supply.” That steam is captured and used for cooling in a closed-loop system.

General Electric estimates that for a typical 480-MW 7H-equipped combined-cycle plant, the period for recovering an initial investment could be shortened by 20 percent compared to more conventional installations.

The G models no longer appear in the most current GE Energy documentation.

7H Orders. Orders for the 7H have come from Sithe Energies Inc for two units for an 800-MW power plant to be located in the upstate region of New York, near the town of Scriba. The Sithe plant project was put on hold in May 2002.

A second order was placed by Hydro Quebec for the 800-MW Suroit facility in Beauharnois, Quebec, Canada. That facility was placed on hold in February 2004.

In November 2004, Calpine Corp signed a Letter of Intent with GE Energy for the joint construction of a power plant based on the H System™. The new facility will be based on two GE 107H combined-cycle systems that will provide a total plant output of more than 775 MW.

In February 2005, Calpine and GE Energy selected Calpine’s Inland Empire Energy Center in Southern California for the North American launch of GE’s H System. The Inland Empire Energy Center is located in the unincorporated community of Romoland in Riverside County, California. It is scheduled to be on-line by the summer of 2008, at which point energy officials have predicted energy supplies might not be sufficient to meet demand. The plant is currently in the construction phase.

The GE Energy Model MS7001FB, rated at 280+ MW for combined-cycle and about 185 MW for simple-cycle operation, offers customers increased efficiency and output, especially for use in combined-cycle operation.

The STAG 107FB has a combined thermal efficiency of 57.3 percent, which is about 1.3 percent greater than that of the STAG 107FA. A STAG 107FB combined-cycle system generates a total of 280.3 MW, at just over 57.3 percent efficiency.

7FB Orders. As of late October 2008, the Frame 7FB had been ordered by the following firms:


GE Model 7000

December 2008

Firm # Ordered States Calpine Corp 5 CA, NY, WI Customer not identified

4 CA

LG&E Energy Corp 6 TX Reliant Energy 6 MS, PA Sithe Energies 18 NJ, NY, PA

Frame 7 Production Locations. In the U.S., the Frame 7 machines are produced in Greenville, South Carolina. In France, the machine is produced by GE in Belfort.

Related News First Two F Technology Gas Turbines Begin Operation in Saudi Arabia – In April 2006, GE announced that two GE Frame 7FA gas turbines had started operating at the Uthmaniyah Cogeneration Plant in Saudi Arabia, becoming the first F technology machines to enter service in the Kingdom.

The two gas turbines are among six F technology units GE has supplied for three cogeneration plants being built by the Tihama Power Generation Co of Saudi Arabia. The largest independent power producer in Saudi Arabia, Tihama Power is a joint venture between International Power of the U.K. and Saudi Oger of Saudi Arabia, an affiliate of the Saudi Arabia Oil Co (Saudi Aramco).

All of the plants are located in Saudi Arabia’s eastern region. Saudi Aramco is supplying the natural gas for the projects and is using the power and steam generated for its processing plants.

The 7FA gas turbines were manufactured at GE’s facility in Greenville, South Carolina. Installation at the Uthmaniyah site began in April 2005. The major contractor for the project was Hyundai Heavy Industries of Ulsan, Korea. (GE, 4/06)

Market Intelligence Service Subscribers: For additional news, go to the online E-Market Alert page located in the Intelligence Center at www.forecastinternational.com and click on the links to the products you subscribe to.

Funding No U.S. government funding for the GE Frame 7 series of gas turbine machines has been identified.

Contracts/Orders & Options Award Contractor ($ millions) Date/Description Black & Veatch N/A Sep 2006 – Black & Veatch was awarded a contract to install two

150-MW Frame 7 turbines at Tampa Electric Co’s Polk Power Station to provide power during times of peak customer electric demand.

The simple-cycle natural gas turbines will be Units 4 and 5 at the Polk

Power Station, about 40 miles east of Tampa, FL. The Polk power station currently includes a 250-MW integrated coal gasification combined-cycle (IGCC) plant, as well as two 150-MW gas peaking units.

Black & Veatch was to complete the installation of the two 150-MW gas

turbines in Feb 2007. The company previously was awarded contracts for the disassembly and transport of the Polk Power Station’s gas turbines, generators and associated equipment.

GE Oil & Gas N/A Jul 2006 – GE Oil & Gas won a contract to supply two Frame 7 gas

turbine-driven turbocompressor trains to Peru LNG SRL for a new gas liquefaction plant in Pampa Melchorita, south of Lima, Peru. Each train will have two centrifugal compressors.


GE Model 7000

© 20 08 December 2008

Award Contractor ($ millions) Date/Description GE Energy N/A Jan 2005 – Nevada Power Co selected a GE gas turbine for the

expansion of the Harry Allen Generating Station, located 30 miles north of Las Vegas. The GE Frame 7EA gas turbine, rated at 77 MW, entered commercial service in May 2006.

The new GE gas turbine is used in peaking service, with natural gas as

the primary fuel. The machine utilizes GE’s latest DLN combustion system, so NOx emissions are limited to 5 ppm. The air-cooled generator for the project was manufactured in Austria.

GE Oil & Gas <$95 Oct 2004 – GE Oil & Gas was selected to supply major rotating

equipment for Train 5, the latest expansion of the RasGas (II) facility owned by Ras Laffan Liquefied Natural Gas (LNG) Co Ltd in Qatar. The new LNG Train 5 was to be built adjacent to the existing LNG Train 3 that was completed in December 2003, and Train 4. GE Energy also has supplied equipment for these two projects. The Train 5 project was scheduled for completion by the end of 2006.

Under the contract, GE Energy’s oil and gas business was to provide

two Frame 7EA mechanical drive gas turbines, two Frame 6B gas turbine generator packages, one Frame 5D residue gas compressor package, and one Rotoflow Frame 60 turbo expander-compressor. All the gas turbines were to be equipped with dry low NOx combustion systems to meet the stringent NOx emissions levels now required in Qatar.

The equipment was to be supplied through a joint venture including

Chiyoda Corp of Japan and Snamprogetti SpA of Italy, the latter of which received the engineering, procurement and construction contract for the plant.

Timetable Month Year Major Development 1967 Model 7000 granted design go-ahead Aug 1969 First MS7001 prototype becomes operational 1970 First unit installed 1971 30 units installed 1973 First overseas sale of Frame 7 machine Oct 1986 GE announces 7F model 1987 First 7EA installed Aug 1988 GE announces the uprating of 7EA and 7F machines Late 1988 First 7F shipped Feb 1989 Duke Power agrees to take up to 16 7EAs Jun 1991 GE announces 125-MW MS7001E/F machine 1993 MS7001E/F become available Feb 1993 Hartwell Energy LP orders 7FA for simple-cycle peaking duty 2Q 1994 Hartwell Energy 7FA machines begin commercial operation Late 1994 GEPS reports on MS7001EC machine 1994 MS7001EA uprate packages become available 1995 G and H models announced Summer 1999 First 60-Hz version of H model combined-cycle machine sold Nov 1999 MS7001FB introduced at Power-Gen 1Q 2000 First 7H pre-shipment test conducted 1Q-2Q 2000 First 7FB full load test conducted 2001 First shipment of 7FB May 2002 Sithe Energies’ Scriba project canceled


GE Model 7000

December 2008

Month Year Major Development By end of 2003 Start of commercial operation of 7FB-equipped power plants Jan 2004 Hydro Quebec orders two 7H GTs for 800-MW Suroit facility in Canada Nov 2004 Suroit P/P program officially scrapped Nov 2004 Calpine, GE announce plans to build 7H plant in U.S. By end of 2004 Originally intended start of operation of 7H-equipped Sithe Energies power plant Feb 2005 Calpine and GE Energy select Calpine’s Inland Empire Energy Center for North

American launch of GE’s H System. Thru 2017 Continued production of MS7001 gas turbine machine series

Worldwide Distribution/Inventories

At the start of 2008, about 1,975 60-Hz Frame 7 (new series) gas turbine machines had been built and installed in 23 countries worldwide, with the largest number of installations being in the U.S. (1,518 machines). Other nations having a large number of installations include Brazil (24), Japan (54), Korea (ROK) (30), Mexico (36), Saudi Arabia (180) and Taiwan (35).

The total above includes 28 Frame 7E and 7EA machines (5 and 23, respectively) installed for mechanical load drive duty in eight countries worldwide. Variants no longer in active production are not reflected in the table below.

Forecast Rationale The 60-Hz GE Energy Frame 7 gas turbine machine continues to be widely used to meet the capacity needs of utilities and IPPs in the current decade and beyond. Many of these machines are being used in a staged power plant construction concept whereby a facility can evolve from simple cycle to combined cycle and perhaps on to combined-cycle cogeneration, or even to combined-cycle with integrated coal or waste-gas gasification.

It should be borne in mind that because the MS7001 is a 60-Hz machine, its sales opportunities outside the U.S. are limited to Japan, Saudi Arabia, and a small number of other nations worldwide, including selected countries in Central/South America. In Japan, GE’s partner Toshiba is capable of building the 170-MW machine.

There is ongoing interest in the MS7001EA and 7FA for use in simple-cycle operation, and in the 7FA (again), 7FB, and 7H for use in combined-cycle operation, especially given the large number of utilities and non-utility generators that have expressed interest in the Frame 7 in all its variants, for every role from simple-cycle generation to repowering.

Production of the Frame 7 series for the Southeast Asian and Japanese markets is expected to eventually increase when that part of the world regains momentum and begins to order gas turbine machines for its electrical power needs. Hitachi and Toshiba are well-positioned to benefit in the upcoming decade, along with GE Energy itself.

An even more important marketplace emerging for the Frame 7 (for all models, but especially the 7FB and 7H) is Central/South America. The orders from customers in Brazil, Mexico, and Venezuela are just the tip of the iceberg, with more orders expected to come. It would not be inconceivable for GE Energy to seek a fully capable manufacturing site or manufacturing partner in that region.

Despite the previous gloom in the electrical generation marketplace, the Frame 7 family remains popular, especially with a simple-cycle power offering of 85 to 172 MW in the increasingly popular medium- (peaking duty) to high-power (baseload power) bands. Production supporting the next major wave of utility re-equipping should rise noticeably in 2008 or 2009.

In our newly revised production forecast for the decade 2008-2017, GE Energy and its allied firms are projected to build 793 Frame 7 machines of all variants and power outputs. Production by such firms as Bharat, Hitachi, and Toshiba is included in the GE Licensees/Affiliated Firms segment; their individual totals are a small part of total production in the early part of the decade, but are expected to increase during the second half.

Of the 793-unit total, 245 units are projected to be 7FBs and 7Hs, representing nominally 30 percent of the GE production total. Production by GE Energy’s GE Oil & Gas in Italy is included in the GE Energy total.


GE Model 7000

© 20 08 December 2008

The popular 7FA will continue to be the leading model of the Frame 7 series, although from about the mid-point of the decade, the 7FB and 7H should see greater increases than the 7FA.

At least 34 Frame 7EA gas turbine machines were installed through 2008 for various mechanical load drive duties (mainly for compressor drive roles), and we are now issuing a combined production forecast for the MS7111EA and MS7121EA for mechanical load drive

duty. Production models of those two variants are production-line Frame 7EA units that have been slightly modified. We project that 54 7EAs will be built for that marketplace over the course of the decade.

With the announcement that GE and Calpine would build North America’s most advanced combined-cycle power plant in Riverside County, California, it looks as if the Frame 7H is finally moving to a production status after a few near-hits.

Ten-Year Outlook

ESTIMATED CALENDAR YEAR UNIT PRODUCTION

Designation or Program High Confidence Good Confidence Speculative

Thru 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 Total

GE Energy

Model 7000 (Frame 7) (MS7001) E A <> MW 50.0 to <125.0 <> Industrial Power Generation 466 7 8 9 10 10 12 10 10 9 9 94

Model 7000 (Frame 7) (MS7001) E A <> SHP =>20,000 <> Mechanical Drive (Pumps & Compressors) 34 3 4 4 4 4 4 3 3 2 2 33

Model 7000 (Frame 7) (MS7001) F B <> MW =>180.0 <> Industrial Power Generation 7 5 8 12 15 15 15 14 14 14 14 126

Model 7000 (Frame 7) (MS7001) F/F A <> MW 125.0 to <180.0 <> Industrial Power Generation 930 18 24 30 36 36 36 36 36 35 35 322

Model 7000 (Frame 7) (MS7001) F/F A <> SHP =>20,000 <> Mechanical Drive (Pumps & Compressors) 5 4 5 5 5 4 4 5 5 4 4 45

Model 7000 (Frame 7) (MS7001) H <> MW =>180.0 <> Industrial Power Generation 3 3 6 10 12 14 14 14 16 16 14 119

Subtotal 1,445 40 55 70 82 83 85 82 84 80 78 739

MFR Varies

Model 7000 (Frame 7) (MS7001) E A <> MW 50.0 to <125.0 <> Industrial Power Generation 2 2 3 2 1 2 3 3 3 2 2 23

Model 7000 (Frame 7) (MS7001) E A <> SHP =>20,000 <> Mechanical Drive (Pumps & Compressors) 3 1 3 3 4 4 4 3 3 3 3 31

Subtotal 5 3 6 5 5 6 7 6 6 5 5 54

Total 1,450 43 61 75 87 89 92 88 90 85 83 793

Industrial & Marine Turbine Forecast - Gas & Steam Turbines

©2009 August 2009

Rolls-Royce 501-K

OrientationDescription. Single-shaft/cold-end drive and two-shaft/hot-end drive, axial-flow, aero-derivative industrial gas generators and industrial and marine gas turbine machines in the 4-6-MW class.

Sponsor. The 501-K I&M series was privately developed by (then) Allison Gas Turbine, a division of General Motors Corporation.

Power Class. The power output of the Rolls-Royce 501-K series is 3.95-6.4 kWe and 5,500-7,400 bhp.

Status. In production.

Total Produced. At the start of 2009, more than 2,137 501-K machines were supplied to 500 customers in over 40 countries and territories worldwide.

Application. Electrical generation (including combined-cycle and cogeneration); mechanical load drives (compression and pumping); marine power.

Price Range. Approximate costs of the 501-K I&M series are $360-$445 per kilowatt for generation and

$295-$345 per kilowatt for mechanical drive machines. Marine engines/sets are about 0.775-0.825 times that of generation.

For electrical generation (simple-cycle), the generator set (genset) price covers a single-fuel skid-mounted gas turbine, electric generator, air intake with basic filter and silencer, exhaust stack, basic starter and controls, and a conventional combustion system.

For mechanical drive, the price covers a gas-fired gas turbine (without driven equipment) with gearbox, skid, enclosure, inlet and exhaust ducts and exhaust silencer, basic turbine controls, fire protection, starting systems, and conventional combustion system.

Competition. The 501-K series' main competition comes from GE Oil & Gas, Kawasaki, Siemens AG, and Solar.

Contractors

Prime Rolls-Royce Corp http://www.rolls-royce.com/northamerica, PO Box 420, 2001 S Tibbs Ave, Indianapolis,

IN 46206-0420 United States, Tel: + 1 (317) 230-2000, Fax: + 1 (317) 230-4020, Prime

Samsung Techwin Co Ltd http://www.samsungtechwin.com, KIPS Center, 647-9 Yoksam-Dong, Seoul, 135-080 Korea, South, Tel: + 82 2 3467 7114, Fax: + 82 2 3467 7080, Licensee

Outlook 501-K series’ main competition is from GE Oil & Gas,

Solar, Siemens AG, and Kawasaki

501-K line remains competitive for electrical generation and mechanical load drive; it continues to be well established due to company’s modernization efforts

Centrax very active in generating orders for 501-K series

Production funding still expected from the U.S. Navy; RDT&E is waning

38

40

42

44

46

48

50

Uni

ts

Unit Production Forecast 2009-2018

Units 43 42 46 49 48 49 49 49 48 48

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

Page 2 Industrial & Marine Turbine Forecast - Gas & Steam Turbines

Rolls-Royce 501-K

Subcontractor Associated Spring, Group Headquarters

http://www.associatedspring.com, 80 Scott Swamp Rd, Farmington, CT 06032 United States, Tel: + 1 (860) 678-0700, Fax: + 1 (860) 409-4611, Email: [email protected] (Gear Spring)

Cabot Corp http://www.cabot-corp.com, Two Seaport Lane, Boston, MA 46904-9013 United States, Tel: + 1 (617) 345-0100, Fax: + 1 (617) 342-6103 (High Temperature Superalloy Mill Product; Investment Casting)

Cincinnati Gear Co http://www.cintigear.com, 5657 Wooster Pike, Cincinnati, OH 45227-4120 United States, Tel: + 1 (513) 271-7700, Fax: + 1 (513) 271-0049 (High Power Density Reduction Gearing)

Danville Metal Stamping Co Inc http://www.danvillemetal.com, 20 Oakwood Ave, Danville, IL 61832 United States, Tel: + 1 (217) 446-0647, Fax: + 1 (217) 446-3751 (Anti-Icing Cowl Assembly; Baffle Collect Assembly)

Dyna-Empire Inc http://www.dyna-empire.com, 1075 Stewart Ave, Garden City, NY 11530-4812 United States, Tel: + 1 (516) 222-2700, Fax: + 1 (516) 222-1896 (Control Assembly)

Honeywell Aerospace http://www.honeywellaerospace.com, 1300 W Warner Rd, Tempe, AZ 85284 United States, Tel: + 1 (480) 592-5000, Fax: + 1 (480) 496-7811 (Air Turbine Starter)

Honeywell Aerospace http://www.honeywell.com/sites/aero/, 717 N Bendix Dr, South Bend, IN 46620 United States, Tel: + 1 (574) 231-2000, Fax: + 1 (574) 231-3335 (Cable Assembly; Lever Assembly; Body Assembly; Valve Assembly)

Precision Castparts Corp http://www.precast.com, 4650 SW Macadam Ave, Suite 440, Portland, OR 97239-4262 United States, Tel: + 1 (503) 417-4800, Fax: + 1 (503) 417-4817, Email: [email protected] (Structural Casting)

TurboCombustor Technology Inc http://www.tct-inc.com, 3651 SE Commerce Ave, Stuart, FL 34997-4967 United States, Tel: + 1 (561) 287-7770, Fax: + 1 (561) 287-0476 (Combustor; Transition Liner)

Woodward Governor Co http://www.woodward.com, 5001 N Second St, PO Box 7001, Rockford, IL 61125-7001 United States, Tel: + 1 (815) 877-7441, Fax: + 1 (815) 639-6033 (Model 503 Digital Control System)

Comprehensive information on Contractors can be found in Forecast International’s “International Contractors” series. For a detailed description, go to www.forecastinternational.com (see Products & Samples/Governments & Industries) or call + 1 (203) 426-0800.

Contractors are invited to submit updated information to Editor, International Contractors, Forecast International, 22 Commerce Road, Newtown, CT 06470, USA; [email protected]

Technical Data Design Features Compressor. Fourteen-stage (15 in 501-KB7) axial-flow, with fixed stators and inlet guide vanes. Pressure ratio of 9.4 to 13.5. Mass flow is 15.4 to 21.1 kg/sec. Blades are 17-4PH; vanes are 410SS. Stage 1 disc in AMS6260; Stage 2-13 discs of 410SS; Stage 14 of 17 4PH. Cases are of steel, inlet case of aluminum.

Combustor. Six can annular chambers of the through-flow type are enclosed within an outer combustor liner. Models can be equipped for liquid-fuel, natural gas, or dual-fuel operation. Two DC igniters supply ignition. Liners and duct are made of Hastelloy X; casing is made of titanium. Extensive combustor optimization efforts have been undertaken recently by Rolls-Royce (see Program Review).

Gas Generator Turbine. Model 501-K engines are manufactured in single- or two-shaft versions. In single-shaft models, the four axial-flow stages are tie-bolted together: Two-shaft variants use the first two stages to drive the gas producer and the second two stages to drive the power shaft. IN738 blades are held in place by fir-tree roots. All subsequent models now utilize hollow, air-cooled Stage 1 blades and vanes.

Discs are made of Waspaloy, vanes of X40. Turbine casing is of Hastelloy X. Blades and vanes are aluminum diffusion-coated for sulfidation protection. Model 501-KC5 Stage 1 turbine blades are MAR-M246, while vanes are MAR-M509.

Power Turbine. The last two stages of the 501-K turbine section are separated to form a free power turbine. Design speed range is 6,000 to 14,600 rpm.

August 2009

Industrial & Marine Turbine Forecast - Gas & Steam Turbines Page 3

Rolls-Royce 501-K

©2009 August 2009

Stage 1 blades are made of IN738; Stage 2 blades of Waspaloy. Discs are also made of Waspaloy, while vanes are of X40. The power turbine casing is of Hastelloy X, while the vane casing is of Hastelloy C. Two roller bearings and a single ball bearing support the turbine shaft, and carry thrust and axial loads.

Bearings. Five pressure-lubricated, aircraft-type bearings: three roller journal bearings and two thrust ball bearings.

Accessories. Single-shaft versions use a front-mounted gearbox to reduce output speeds from

between 13,600 and 14,600 rpm down to synchronous generator speeds. Starting is normally by means of an air turbine, but electric or hydraulic starting is available.

Control System. Manual, semiautomatic, or fully automatic operation is accomplished using a Woodward Electronic Control/Governor System. The system provides multiple monitoring features and protective shutdown in the event of excessive vibration or other abnormal operation.

Dimensions. The approximate dimensions and weights of the Rolls-Royce 501-K series-equipped gensets (complete packaged units) are as follows:

APPLICATION = ELECTRICAL GENSETS APPLICATION = MECHANICAL DRIVE SETS Metric Units English Units Metric Units English Units Model L x W x H (meters) L x W x H (feet) L x W x H (meters) L x W x H (feet) 501-KB5 9.0 x 2.7 x 3.0 30.0 x 8.7 x 10.0 – – Weight 15,875 kg 35,000 lb – – 501-KB7 9.0 x 2.7 x 3.0 30.0 x 8.7 x 10.0 – – Weight 16,328 kg 36,000 lb – – 501-KH5 (a) 9.0 x 2.7 x 3.0 30.0 x 8.7 x 10.0 – – Weight 16,328 kg 36,000 lb – – 501-KC5 – – 6.4 x 2.4 x 3.0 21.0 x 8.0 x 10.0 Weight – – 11,400 kg 25,000 lb 501-KC7 – – 6.4 x 2.4 x 3.0 21.0 x 8.0 x 10.0 Weight – – 11,800 kg 26,000 lb (a) Water injected.

The approximate dimensions and weights of the Rolls-Royce AG9140 and AG9140RF ship service generators for marine duty are as follows:

APPLICATION = MARINE SERVICE GENERATOR Metric Units English Units Machine Machine Model L x W x H (meters) L x W x H (feet) Dry Weight Dry Weight AG9140/40RF 8.65 x 2.37 x 3.38 28.395 x 7.8 x 11.1 29,257 kg 64,500 lb

Performance. The approximate performance parameters of the Rolls-Royce 501-K series-equipped generator sets (complete packaged units) are as follows (ISO, no losses; PT speed of 14,600 rpm):

APPLICATION = ELECTRICAL GENSETS GG GG Rating Heat Rate Compression Compression Exhaust Exhaust Model ISO Base LHV Ratio Stages Temp Mass Flow 501-KB5 3,938 kW 12,266 kJ/kWh 9.4 14 560°C 15.4 kg/sec 501-KB7 5,300 kW 11,380 kJ/kWh 13.5 1 + 14 501°C 21.1 kg/sec 501-KH5 (a) 6,420 kW 9,037 kJ/kWh 9.4 14 530°C 18.3 kg/sec (a) Water injected.


Rolls-Royce 501-K

The approximate performance parameters of the Rolls-Royce 501-K series-equipped mechanical load drive sets (complete packaged units) are as follows (ISO, gaseous fuel, no losses; PT speed of 13,600 rpm):

APPLICATION = MECHANICAL DRIVE SETS GG GG Rating Heat Rate Compression Compression Stack Exhaust Model ISO Base LHV Ratio Stages Temp Mass Flow 501-KC5 5,500 bhp 8,495 Btu/hph 9.4 14 571°C 31.2 lb/sec 4,100 kW 12,170 kJ/kWh 15.5 kg/sec 501-KC7 7,400 bhp 7,902 Btu/hph 13.5 1 + 14 520°C 46.2 lb/sec 5,500 kW 11,340 kJ/kWh 20.9 kg/sec The approximate performance parameters of the Rolls-Royce AG9140 and AG9140RF gas turbine for marine duty in a ship service generator are as follows (at 100°F, S/L, with 6″ inlet/10″ exhaust losses and using DF2 fuel):

APPLICATION = SHIP SERVICE GENERATOR With Bleed Without Bleed Continuous Power Output (a) 2,500 kW 3,000 kW Maximum Power Output (b) 4,500 kW 4,500 kW Fuel Rate (a) 15,375 Btu/kW-hr 13,250 Btu/kW-hr Turbine Speed 14,340 rpm 14,340 rpm Generator Speed 1,800 rpm 1,800 rpm Firing Temperature 2,142°F 2,142°F Exhaust Gas Flow 29.0 lb/sec 31.1 lb/sec Exhaust Gas Temperature 1,117°F 1,097°F Engine Bleed Capacity 2.37 lb/sec 0.0 (a) Includes generator and gearbox losses. (b) For emergency, use up to five minutes.

Variants/Upgrades AG9130/AG9140. Rolls-Royce has evolved a complete ship service gas turbine generator set under the designation AG9130. A derivative of the Model 501-K34/KB5, the AG9130 is rated at 2,500 kW continuous with air bleed, 3,000 kW continuous without air bleed, and 4,500 kW emergency service. The unit, entirely a Rolls-Royce/Allison product, was designed for marine applications on board the U.S. Navy DDG-51 Arleigh Burke class vessels. The AG9130 meets U.S. Navy requirements for shipboard generation. It features an automatic dual-voltage regulation system, low-pressure air starting with silencing, and a generator with the lowest airborne noise signature in the service. It is completely self-contained to include all controls, sea water systems, expansion joints, and a fire damper.

Allison began working under a contract awarded in March/April 1986, and shipped the first unit to Bath Iron Works, located in Bath, Maine, in 1987. The AG9130 is the replacement for the 501-KF package; three such packages are used in each vessel.

The AG9140 incorporates significant maintainability and reliability upgrades and technology enhancements, based on lessons learned from the deployment of the early ships in the class. These upgrades have provided

the U.S. Navy with the latest generator set technology. Allison began shipment to Bath Iron Works in 1994.

Features of the AG9140 include the generation of 3,000 kW of 440 V, three-phase power, local or remote control, removable panels and doors, a built-in maintenance beam and hoist, and high corrosion-resistance. It has been MIL-G22077 qualified and shock tested per MIL-S-901C. Additional features of the AG9140RF include a built-in mechanical starter (250-KS4), dark ship start from batteries only, redundant start capability, and Full Authority Digital Control (FADC).

The AG9140 is on board the ROK's three KDX-3 destroyers (see Korea KDX-3 Class Destroyers below).

ATS (Advanced Turbine System). The U.S. Department of Energy, the Chicago-based Gas Research Institute, and Rolls-Royce Engine Company are in the process of developing what is described as a new generation of gas turbines that utilize a natural gas-fueled catalytic combustion system. The intent is to lower the emission levels to ultra-low ratings – reportedly a first in gas turbine technology. Component tests began in 1999, followed by a full-scale demonstration and an 8,000-hour durability test in 2000.

August 2009


Rolls-Royce 501-K

©2009 August 2009

Work at Rolls-Royce on this effort is ongoing, although at a somewhat reduced level of activity.

Early tests showed that the ATS reduced NOx emissions by 0.9 tons per year and CO2 emissions by 5.8 tons annually. Rolls-Royce estimated that the ATS could reduce the fuel costs of turbine operators by about $380,000 a year.

The ATS is targeted for modular and distributed power generation markets, both significant growth areas in the power generation arena thanks to ongoing deregulation in the U.S. and elsewhere. Funding for the program is provided by the U.S. DoE.

Meanwhile, San Diego-based Solar Turbines is developing a recuperated-cycle industrial turbine under the same ATS program. Larger systems (400+ MW) for utility-scale applications are being developed by GE and Siemens Westinghouse.

501-KB. The Model 501-KB is a single-shaft generator drive with a power output of 4,450 kW at base load, and 5,420 kW at intermediate power on distillate or natural gas fuels. The 501-KB3 and 501-KB4 were both introduced in 1994. The 501-KB3 offers a low mass flow (28 lb/13 kg per second) with a relatively high exhaust temperature (1,051°F/566°C). The 501-KB3 has a thermal efficiency of 26.5 percent. The 501-KB4 is a 4-MW machine rated for standby duty, and features liquid fuel with natural gas and dual-fuel options. The 501-KB4's thermal efficiency rating is 29.7 percent.

The 501-KB5 is available with high temperature capability (1,895°F TIT) Stage 1 turbine blades and vanes, either as the 3.94 MW 501-KB5 or as a retrofit enhancement kit; that capability increases blade life by

30 percent to 40,000 hours. The 501-KB17 is the onboard generating set for the U.S. Navy CG-47 class ships.

501-KB7. In June 1991, (then) Allison announced that it was developing an increased power version of the 501-K single-shaft engine. The 501-KB7 is the most powerful offering, providing 5,300 kWe continuous. The design added a boost module to the front of the current 501-K. This module incorporates the functions of the current air inlet housing assembly, but adds a compressor stage consisting of 29 compressor blades and 35 stator vanes. The KB7 utilizes the PTO shaft arrangement as produced for the 501-KB5/KH models.

For the 501-KB7, the rear turbine bearing support, which is also the turbine exhaust section, was redesigned to provide for increased airflow with the addition of the boost module. The Stage 4 turbine blades were also redesigned to reduce losses in the exhaust system. Other changes or modifications from earlier models include the use of thermal barrier-coated vanes in the turbine section and effusion-cooled combustion.

501-KF. The Model 501-KF is a two-shaft marine propulsion engine that powers the Boeing Jetfoil in commercial and military service (designated 501-K20A by Boeing). Production Model 501-KFs are rated at 4,330 horsepower (3,229 kW) at a gas generator speed of 13,885 rpm and power turbine speed of 13,820 rpm. Maximum rated power (intermittent) is 5,420 horsepower at 14,560 gas generator rpm and at 13,820-rpm power turbine output speed. Many 501-KF units have been supplied to the U.S. Navy by Stewart & Stevenson (for more details, see Program Review below).

Program Review Background. The current manufacturer is Rolls-Royce plc, Rolls-Royce Corp, located in Indianapolis, Indiana, USA. This series of gas turbine machines is produced in Indianapolis.

OEMs/EPSs – Compressors & Pumps: Dresser-Rand Co, Turbo Products Division, based in Olean, New York, USA, is the current Original Equipment Manufacturer (OEM)/Engineered Product Supplier (EPS) for compressors and pumps.

OEMs – Marine Drive:

Cincinnati Gear Company, Cincinnati, Ohio

Kawasaki Heavy Industries Ltd, Kobe, Japan

Licensees/Distributors – Generator Sets:

CEC-STR Distribuicao de Turbinas, Rio de Janeiro, RJ, Brazil

Centrax Ltd, Newton Abbot, Devon, U.K

Detroit Engine & Turbine Co, Adelaide, SA, Australia

Samsung Techwin, Seoul, Korea (ROK)

Tominaga & Co Ltd, Tokyo, Japan

U.S. Turbine Corp, Maineville, Ohio (now a part of Rolls-Royce Energy Systems Inc, Power Generation)

The Rolls-Royce I&M Model 501-K series of gas generators and gas turbine machines are derivatives of


Rolls-Royce 501-K

the well-known and prolific military T56 turboprop engine, which has provided power to such aircraft as the Lockheed P-3C, Lockheed C-130, and Grumman E-2C. Over 16,000 aero T56 engines were built through 2000 (including the civil aero Model 501-D) by Allison and licensee IHI.

The I&M Model 501-K draws heavily upon the design features of the T56, and has inherited the aviation engine's high level of performance, durability, and reliability. The I&M Model 501-K series machines are currently rated at 3.9 MW and 5.2 MW for generation duty.

The first industrial installation occurred in 1962, when DeLaval of Houston, Texas, fabricated a compression set using a 501-K as the prime mover. Since that time, the gas turbine has found wide use in the industrial and marine markets, and is handled by many OEMs, distributors, and EPSs.

Major Licensees, Distributors, Packagers, OEMs, and EPSs. Rolls-Royce's Engineered Product Suppliers combine responsibilities of the Rolls-Royce traditional distributors and Original Equipment Manufacturer; EPSs supply the same product and service as the 501-K distributors, along with providing a mechanical driver for compressors and pump applications.

The following are the major firms currently working with Rolls-Royce on the Model 501-K:

IHI. Ishikawajima-Harima Heavy Industries is a licensee of Rolls-Royce in Japan. The company builds the aero T56 turboprop for the P-3C, also built under license in Japan. It has been a producer of the industrial variant of the I&M Model 501-K, under the designation IM400. IHI offered both stationary and mobile configurations of the IM400. IHI is no longer an active licensee of the I&M Model 501-K.

Stewart & Stevenson. Stewart & Stevenson has long been an innovative packager of gas turbines and driven-equipment products; it can act as a single-source for the prime mover, driven equipment, and, when desired, for heat recovery and combined-cycle apparatus. S&S has packaged more Model 501-K gas turbines and accumulated more time on the 501-K for industrial applications than any other supplier; more than 150 units have been shipped to the U.S. Navy alone.

Configured as a single-shaft machine for generator set applications, the 501-K is a prime mover for hundreds of installations worldwide. For compressor and marine drive, the 501-K is available in a two-shaft

configuration (501-KSS) to provide the flexibility of variable-speed operation.

The S&S 501-KSS5 two-shaft gas turbine engine is an advanced version of the already proven 501-KF gas turbine. S&S has enhanced the KF power turbine design to provide increased torque capability, lower fuel consumption, and a wider range of operation. The 501-KSS5 is considered an excellent prime mover for marine propulsion and mechanical drive.

Stewart & Stevenson Gas Turbine Products was purchased by General Electric in 1998, ending that entity's work with Allison on the 501-K.

Centrax. This U.K.-based firm previously offered the CX350, and currently offers the CX501 generator set powered by the Model 501-KB3, -KB5, -KN, -KB7, and -KH gas turbine machines. Its gensets supply electrical power in a variety of applications, and have been included in cogeneration installations.

In 1990, Centrax received an order for the first steam-injected 501-KH machine in Europe. The project was a combined heat and power (CHP) district heating scheme at Osimo, Italy. The equipment incorporated the Cheng Cycle method of reinjecting steam produced by the exhaust back into the machine's combustion casing. The main contractor for the scheme was the Austrian engineering firm SGP-VA Energie und Umwelttechnik GmbH, which is the licensee for Cheng Cycle in Europe; it supplied all support equipment other than the Centrax equipment.

Centrax has also provided a pair of CX501-KB5s for a CHP plant at Par Harbor, Cornwall, England, owned by ECC International in partnership with BP Energy Ltd. The plant successfully completed commissioning tests in the first half of 1992. The generator sets run on natural gas at 12 bar pressure to provide 3.7 MW each.

US Turbine Corporation. US Turbine Corp (now a part of Rolls-Royce Energy Systems Inc, Power Generation) has offered a full range of gas turbine and engine generating sets in the 660-51,580 kWe range. It has offered the 501-K in its generator sets under the designations UST3400 (501-KB), UST3800 (501-KB5), UST4000 (501-KB5S), UST5000 (501-KB7), UST5600CC (501-KH), and UST6600CC (501-KH5), the latter two being fully steam-injected systems (Cheng Cycle system optimization).

U.S. Turbine and Standard Aero Ltd announced in 1995 that they had initiated a cooperative service organization to provide comprehensive site maintenance, parts support, and overhaul and repair services to users of the Model 501-K. Standard Aero and U.S. Turbine opened

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Rolls-Royce 501-K

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a jointly operated aftermarket support facility at San Jose (California) Airport in support of the venture.

Tominaga. Tominaga & Company Ltd of Japan has supplied 501-K series engines to Hitachi Zosen for packaging, as well as performing total service on its own. Tominaga Model 501-K generator sets are designated TM501KB-301 (501-KB) and TM501KB5-351 (501-KB5). Base load ratings for these two gensets are 3,100 and 3,620 kW, respectively, at ISO conditions. Mechanical drive machines are designated TM501KC-301 and TM501KC5-351; continuous ratings are 5,250 horsepower and 5,750 horsepower.

Turbomeca. In 1998, France's Turbomeca (a unit of the Snecma Group's Propulsion Branch) indicated that it would take up the Allison 501-K gas turbines for distribution in Europe, under the designations TM4000 and TM5000. The machines give Turbomeca a high-end power band.

Samsung Techwin. Among the newest suppliers and distributors is Samsung Techwin in the Republic of Korea. It is building the Rolls-Royce AG9140 gas turbines under license for the three KDX-3 destroyers. The first vessel launched in May 2007, and the remaining vessels should be launched in 2010 and 2012.

Industrial Applications Dual-Fuel Cycle. The dual-fuel cycle was invented by Dr. Dah Yu Cheng. Rolls-Royce Model 501-KHs have been tested and installed for commercial operation with Cheng Cycle equipment. Heat recovery steam generators (HRSGs) produce high-pressure and high-temperature steam for reinjection into the gas turbine combustion chamber. The Model 501-K, for example, can produce up to 7 MW of electric power with the maximum use of injected steam, and provide thermal efficiencies of up to 50 percent.

The first installation of a Cheng Cycle gas turbine was by Dr. Cheng's International Power Technology (IPT) at California State University. The second Rolls-Royce Model 501-K Cheng Cycle installation is at Sunkist Growers in California, where two Model 501s are now in service producing up to 14 MW of power and variable amounts of process steam for Sunkist food processing.

The Kalina Cycle is the second dual-fuel cycle that has been explored. Kalina involves the use of ammonia/ water injection, which greatly increases effective power.

Both new cycles, while producing much higher outputs and thermal efficiencies, also greatly reduce the air pollutant levels versus simple-cycle machines. Indeed, IPT states that the Sunkist installation meets the NOx

standard of 25 ppm for the San Francisco area and 9 ppm for all of southern California, all without the use of expensive selective catalytic reduction (SCR) equipment normally specified by the state.

In 1987, it was announced that Turbonetics Energy Inc of Latham, New York, was developing a steam injection system for the 501-K. The firm, working with the support of the Gas Research Institute, ran a test program of its system at the General Motors Corp Hydra-matic Division facility in Warren, Michigan, in the U.S.

Turbonetics' system is primarily targeted at the replacement industrial boiler market. The system can boost the power output of the turbine from 3 MW to 4 MW, and can increase the electric power generating efficiency from 27 percent to 35 percent. In addition, supplementary gas firing can increase the boiler's steam delivery from a nominal 8,840 kg/hr to 15,875 kg/hr, and raise overall system thermal efficiency from 60 percent to 85 percent.

NOx Reduction Efforts. Rolls-Royce focused on technologies that would reduce emissions and allow the burning of alternative fuels. For its gas turbine engines, work has been centered on the combustion system. The work bore fruit in the LE4 Dry Low Emission Combustion Configuration for the 501. The LE4 utilizes lean premix and fuel staging to reduce NOx formation and enhance the operational range of the turbine, while maintaining low levels of CO and providing combustion stability.

Rolls-Royce also worked on a direct coal-fueled turbine and conducted component development tests under a U.S. DoE contract. A full-scale combustor (70 MMBtu/hr) has successfully been run on 100 percent coal water slurry (CWS) fuel. Separately, an engine with an external combustor configuration has successfully been run on distillate fuel; engine tests using the CWS external combustor were completed at the end of 1990.

To further explore combustor capabilities and minimize the fuel costs for future commercial applications, a production-standard 501-KB5 machine was successfully tested in August 1991 during a four-hour test using the ground coal and water mixture. Data from the test showed complete and stable fuel combustion and turbine output performance to base load design conditions.

In addition to work on emission technology, Rolls-Royce has improved the durability of the combustion system. On the 501-K, Rolls-Royce has developed an effusion-cooled combustion liner that uses laser-drilled holes in the walls of the liners to lower


Rolls-Royce 501-K

temperatures by 300°F to 400°F. The new liners were initially field-tested in 1991 and are now available on the 501-KB7.

In May 1993, Catalytica Inc (Mountain View, California) and Allison announced that they had signed a Letter of Intent for a joint program to develop an ultra-low emissions catalytic combustion system for the 501-K industrial engine. The intent of the program is to provide an engine with NOx emissions that meet the most stringent emission requirements worldwide.

Marine Applications. Model 501-K gas turbines are in use as propulsion drive systems and shipboard generation sets for both military and civil applications.

Spruance Class Destroyers. In the early 1970s, the U.S. Navy ordered 31 8,040-ton DD-963 Spruance class destroyers. Powered by four GE LM2500 gas turbines in a COGAG (combined gas and gas) mode and using three 501-K17-based shipboard generation systems, these were the first all-gas turbine units in operation with the Navy. The 501-K17s were the first gas turbines to pass the U.S. Navy's 3,000-hour salt injection endurance test in May 1971.

The Rolls-Royce/Allison units provide 2 MW of net generator output power on a 100°F (38°C) day with 2.37 lb/sec (1.07 kg/sec) of compressor bleed loss. In addition to the 31 units built, four similar designs were ordered by Iran, featuring different weapons systems and onboard facilities. However, those were canceled following the Iranian revolution. All used the 501-K17 generation systems packaged by Stewart & Stevenson.

The Spruance class vessels were laid down in the period from November 1972-April 1978. As of mid-2006, only three vessels remained in the Navy's inventory.

Ticonderoga Class Guided Missile Cruiser. Building on the proven hull and machinery of the DD-963s, the Navy developed the 9,407-9,590-ton Ticonderoga class Guided Missile Cruiser (AEGIS cruiser), intended for the highly sophisticated AEGIS weapons system. The lead ship, the USS Ticonderoga (CG-47), was launched in 1981. By July 1994, all 27 vessels had been commissioned.

Three 501-K17 generation sets have been installed, although each has increased capacity to accommodate the power demands of the AEGIS system. The ships operate in high-density, high-threat areas with carrier battle groups, as well as separately with associated escorts. Aboard the AEGIS cruisers, the 501-K17s have a rating of 2.5 MW.

The Ticonderoga class vessels were laid down in the period from January 1980-October 1991. As of

mid-2006, 25 vessels of this type were in service with the U.S. Navy.

Arleigh Burke Class Guided Missile Destroyer. The Navy developed a new 8,422-9,035-ton class of destroyer, incorporating a somewhat less capable AEGIS system; ostensibly, the vessels are to work in conjunction with the CG-47 units. The Navy selected the LM2500 package and the 501-K34 genset arrangement. The use of the genset enhances logistic and maintenance capabilities and facilitates exchanges of spare parts between ships. The initial ship of the Arleigh Burke class, the DDG-51, was commissioned on July 4, 1991.

As of mid-2006, 28 Arleigh Burke (Flight I and II) class guided missile vessels were in U.S. Navy service. In addition, 28 Arleigh Burke (Flight IIA) class vessels had been laid down, out of a total of 34 vessels planned; all Flight IIA vessels are in U.S. Navy service.

Note: The Japanese MSDF has four Kongou class destroyers/frigates in its inventory. The vessels are an enlarged and improved version of the Arleigh Burke class vessels, with a lightweight version of the AEGIS system. While the vessels are powered by four GE LM2500 gas turbines as in the Arleigh Burke class, it is considered unlikely that the MSDF vessels also employ 501-K gas turbines, utilizing Japanese-design machines instead. The Kongou class vessels were laid down in the period from 1990-May 1995.

Pegasus Hydrofoil. Saudi Arabia has one Pegasus class 115-ton hydrofoil vessel, the Al Aziziah. The vessel was ordered in 1984 from Lockheed and subcontractor Boeing; it was delivered in 1985. The vessel has two 501-KF20A gas turbines and two Detroit Diesel 8V92 diesel engines.

Korea KDX-3 Class Destroyers. The Republic of Korea's KDX-3 vessels are a further development of the KDX-2 destroyers, but optimized for anti-air warfare.

Each vessel has a displacement of 7,000 tons, and each is 166 meters (544.6 ft) in length. The first vessel launched in May 2007, and the remaining vessels should be launched in 2010 and 2012.

Rolls-Royce AG9140 gas turbines are currently being built under license by Samsung Techwin for the three KDX-3 destroyers.

In early 2006, information had been issued regarding the choice of GE LM2500 gas turbine propulsion machinery of the KDX-3. Korea's KDX-2 and KDX-1 destroyers are also GE LM2500-powered.

Boeing Jetfoil. The Jetfoil was begun as a private venture by Boeing Marine Systems Division, Seattle,

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Rolls-Royce 501-K

©2009 August 2009

for the commercial passenger ferry sector. The initial service date was April 1975. Two 501-Ks power the craft at speeds up to 45 knots when foil-borne, and current production variants include hydrodynamic and foil improvements. The ships are designated Model 929-100T and 929-115, with the latter launched in 1978.

An estimated 25 Allison-powered Jetfoils and similar surface craft operate worldwide.

Westermoen Ferry. Two 501-K engines provide power for Westermoen's W-100T catamaran ferry in service in Norway. The 100-ton vessel has capacity for up to 250 passengers and provides high-density transportation at speeds up to 45 knots (83.3 km/h), depending upon the sea conditions. With reserve fuel, the W-100T has a range of 418 nautical miles (774 km). Configuration as an offshore platform workboat has been explored.

Halter Marine Company. A single 501-K powers the American Enterprise, a 32-meter, 80-ton workboat in service in the Gulf of Mexico. Designed by Halter Marine of Louisiana, the boat has capacity for up to 82 passengers with reduced cargo, or 20 metric tons of cargo without passengers. Cruise speed is provided by two Detroit Diesel reciprocating compression-ignition engines; both the GT and diesels drive Rocketdyne waterjet pumps.

Magnum Marine. U.S. boat designer/builder Magnum Marine unveiled a 63-foot (19.2-m) 18-ton Super Yacht Magnum 63 at the 1985 Miami International Boat Show. The craft is powered by an Allison/Stewart & Stevenson Model 501-KF gas turbine providing 4,500 shp and speeds in excess of 60 knots (111 km/h).

Antifouling Compressor Coatings Evaluation. The Naval Surface Warfare Center, Carderock Division

(NSWCCD) Gas Turbine Emerging Technologies Code 9334 was tasked by NSWCCD Shipboard Energy Office Code 859 to research and evaluate fouling resistant compressor coatings for Rolls Royce Allison 501-K Series gas turbines. The objective of these tests was to investigate the feasibility of reducing the rate of compressor fouling degradation and associated rate of specific fuel consumption (SFC) increase through the application of anti-fouling coatings Tests, which were conducted at the Philadelphia Land Based Engineering Site (LBES).

Testing was first performed on the existing LBES 501-K17 gas turbine, which had an uncoated compressor. The compressor was then replaced by a coated compressor, and the test was repeated. The test plan consisted of injecting a known amount of salt solution into the gas turbine inlet while gathering compressor performance degradation and fuel economy data for 0-, 500-, 1,000-, and 1,250-KW generator load levels. This method facilitated a direct comparison of compressor degradation trends for the coated and uncoated compressors operating with the same turbine section, thereby reducing the number of variables involved. The collected data for turbine inlet, temperature, compressor efficiency, and fuel consumption were plotted as a percentage of the baseline conditions for each compressor. The results of each plot show a decrease in the rates of compressor degradation and SFC increase for the coated compressor compared with the uncoated compressor. Overall test results show that it is feasible to utilize antifouling compressor coatings to reduce the rate of specific fuel consumption increase associated with compressor performance degradation.

Funding U.S. Navy Ship Propulsion/Power Procurement. The U.S. Navy continues to request funding for the procurement of the marine 501-K gas turbine. In the FY09 Department of Defense Budget submission (May 2009), the Navy sought funds under the category "Other Procurement, Navy, BA 1: Ship Support Equipment, P-1 Item Nomenclature = Allison 501-K Gas Turbine (81GF) (0120)."

Note: The U.S. Navy continues to refer to the manufacturer of the 501-K engine/machine as Allison.

U.S. Navy documentation contains the following information pertaining to the Allison (more accurately, Rolls-Royce) 501-K gas turbine:

The 501-K Series Gas Turbines are used to drive electrical generators in Ship Service Gas Turbine Generators (SSGTG). The 501-K17 is used on the CG-47 Class ships. The501-K34 is an upgraded version used on the DDG-51 Class ships and is not interchangeable with the 501-K17.


Rolls-Royce 501-K

501-K34 Stock Rotating Spares (GF001) The Stock Rotating Spares Program provides an engine as a single assembly for the replacement of an engine requiring depot repair. The current 501-K17 engine is being replaced by the upgraded (more powerful) 501-K34 engine commencing with the DDG-51 Class. The 501-K34 upgraded engine can only be replaced with another 501-K34 upgraded engine. The 501-K34 inventory objective is 22 units. All 22 units have been procured through FY 2007. In addition, the RRC-250-KS4 gas turbine engine has been introduced into the DDG-51 Class Destroyers, as part of the starting system for the 501-K34, commencing with DDG-78. A spare pool of 10 KS4 engines is required to ensure adequate sparing. Ten units have been procured through FY07.

Modification Program (GF007) Allison 501-K Gas Turbines are identified as the number one fleet issue by the Top Management Attention/ Top Management Issues (TMA/TMI) Program, the Combatant Technical Issues Conference (CTIC), and the DDG-51 Top Tech Issue Program. Procurement of improved hardware for installation in the 501-K gas turbine is essential to increase engine reliability, Mean Time Between Removal (MTBR), and maintainability. Analysis of 501-K engineering performance data, TMA/TMI, Metrics, the DDG-51 Top Tech Issues, CTIC, and the component improvement program has identified necessary improvements to correct 501-K deficiencies. The modifications will reduce failure rates of system components, improving 501-K and SSGTG readiness, and address the Fleet's top maintenance and reliability issues. The additional requirement in FY 2007 and out will be used to resolve additional issues identified by the TMA/TMI, Metrics, the PESC, and the DDG-51 Top Tech Issues Programs. The specific additional issues addressed are intake systems, with a new type air filtration system that will reduce maintenance and increase engine life.

Special Support Equipment (SSE) (GF009) Procurement of Gas Turbine SSE is required to provide increased SIMA and depot repair capability to support the CG-47 and DDG-51 class ships. SIMA capability is enhanced by providing them the SSE necessary to reduce engine change-outs and is required to incorporate new modifications that will eliminate deficiencies identified through the TMA/TMI, Metrics, and the DDG-51 Top Tech Issues Programs, and enhance MTBR reliability and maintainability. Procured SSE supports the depot by increasing repair capability and allowing installation of new modifications that will eliminate deficiencies identified through the TMA/TMI, Metrics, and the DDG-51 top Tech Issues Programs, and enhance MTBR reliability and maintainability.

Full Authority Digital Control (FADC) (GF015) Funding will be used to procure and install the replacement for the Local Operating Panel with the FADC that will upgrade reliability and maintainability of the control system. Those units will be installed on both the DDG-51 and CG-47 class ships. Three FADCs are required on each ship. Procurements will complete in FY08.

Production Engineering (GF830) The review and approval of any production contract technical documentation or the separate development of this documentation to include: technical manuals, signal flow diagrams, PMS, production drawings, Provisioning Technical Documentation (PTD), and Allowance Parts Lists (APLs) and engineering in support of final design reviews.

Electric Starter (GF016) Gas turbines are started with pneumatic (air) starters: these are maintenance-intensive and complex. In FY06, we will start to backfit the fleet with electric starters.

Optical Flash Detector (GF017) This sensor will detect and record an irregular start in the engine, then notify the operator that maintenance is required. This new technology will increase the life of the engine.

Hot Section Replacement (GF018) The current hot section (blades and blade track) will benefit greatly by utilizing different coatings and a metal, versus a ceramic blade track. We have evaluated several types, and will begin to procure the best replacement in FY08.

Funding for Cost Codes GF001, GF007, GF009, GF010, GF830, GF016, and GF017 is identified below, as contained in the U.S. Navy's FY10 budget submission of May 2009.

U.S. NAVY PROCUREMENT FUNDING

FY08 FY08 FY09 FY09 FY10 FY10 QTY AMT QTY AMT QTY AMTGF001 501-K34 1 1.35 - - - -GF007 Modific. Prog. - 6.34 - 3.48 - 6.41GF009 Spec. Support Equip. - 0.26 - 0.26 - 0.26GF015 FADC 15 5.85 10 4.00 10 4.00GF830 Production Engrg. - 0.16 - 0.15 - 0.15

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Rolls-Royce 501-K

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FY08 FY09 FY09 FY10 FY10 FY08

QTY AMT QTY AMT QTY AMTGF016 Electric Starter 2 0.56 2 0.58 2 0.58GT017 Optical Flash Det. Sys. - - - - - -GF018 Hot Section Replacement - - 10 2.0 10 2.0 All dollar amounts are in millions of FY09 U.S. dollars.

Beyond FY08, the total planned funding request is as follows (as of March 2009): FY09, $9.44 million; FY10, $9.4 million; and FY11, $9.2 million.

U.S. Navy RDT&E. Funding for the Rolls-Royce Marine 501-K machine has been provided/sought under several U.S. Navy program elements, as follows:

In 1970, PE#63508N, Ship Propulsion System (Advanced) was initiated to develop advanced gas turbine propulsion and auxiliary power systems for U.S. naval combatants. It was the progenitor of the GE LM2500, Rolls-Royce 501-KF, AlliedSignal Garrett IE 831 (now Vericor ASE 8), Pratt & Whitney FT9, and Solar Turbines Rankine Cycle Energy Recovery System. Recent emphasis has been on improvements to the LM2500 propulsion systems and 501-KF generating systems, the since-canceled RACER project, and the LM3000 Intercooled, Recuperated (or Regenerative) Cycle (ICR) gas turbine.

Allison 501-K funding has been awarded under PE#0603508N and PE#0603573N. No 501-K funding has been awarded in PE#0603508N since FY99. Non-501-K-related funding can be found in PE#0603573N.

In the FY07 Department of Defense Budget submission (February 2006), the Navy sought funds under RDT&E Budget Activity 7, PE#0708011N, Industrial Preparedness, Project R1050, Manufacturing Technology. Work on the 501-K machine is contained in the first of five subefforts, "Metals Processing and Fabrication" (excluding the FY05-FY06 congressional plus-ups).

Work identified in that PE's "Accomplishments" and "Plans," in the subeffort "Metals Processing and Fabrication," includes the following:

A. FY06 Accomplishments Completed Hot Section Corrosion Protection for 501-K34 Gas Turbine effort.

B. FY07 Plans Complete Turbine Inspection Techniques effort.

C. FY08 Plans (No tasks specifically identifying the 501-K engine/machine).

D. FY09 Plans (No tasks specifically identifying the 501-K engine/machine).

The following top-line funding is for all activities within Project R1050; Industrial Preparedness: Metal Processing line is funding solely for the sub-effort Metals Processing and Fabrication.

U.S. NAVY RDT&E FUNDING

FY08 FY08 FY09 FY09 FY10 FY10 QTY AMT QTY AMT QTY AMT PE#0708011N R1050 Manuf. Technology - 59.45 - 57.32 - 56.68 (Metals Processing) - 19.72 - 12.9 - - All dollar amounts are in millions of FY08 U.S. dollars.

Beyond FY09, the total planned RDT&E request for PE#0708011N, Project R1050, is as follows (as of May 2009): FY10, $58.92 million and FY11, $59.83 million.


Rolls-Royce 501-K

Contracts/Orders & Options Award

Contractor ($ millions) Date/Description Centrax Ltd N/A Aug 2006 – Centrax has won an order from Portugal to supply a generator set to the

Continental Tyres plant in Lousado, near Porto. The CX 501-KB7 DLE package has been sold to Enerlousado, a special-purpose Joint Venture CEM company between Finerge and TP (Sociedade Termica Portuguese SA). The 5.2-MWe Centrax package, powered by the Rolls-Royce 501-KB7 gas turbine, is coupled to an oversized 15-kV generator. The size of the generator will help to counter any instability of supply from the Portuguese electricity grid.

Centrax Ltd N/A Jun 2006 – Centrax has been awarded a contract to supply a CX501-KB7 gas turbine-powered generator set to the Tunisian paper mill, Sotipapier. The new 5.2-MWe package is the first generator set sold by Centrax into Tunisia. The Centrax unit is natural gas-fueled and will be used for cogeneration at the Sotipapier paper mill in the town of Belli, which is approximately 35 kilometers southeast of Tunis.

Centrax Ltd N/A May 2006 – Centrax was awarded an order from Elyo, part of Suez Energie Services, to supply two CX501-KB5 generator sets. The sets will be used to provide power for Goodyear's two Goodyear Dunlop tire plants in Amiens. The Centrax packages will be operated in a cogeneration capacity.

Centrax Ltd N/A Jan 2006 – Centrax was awarded an order for a 3.5-MWe CX501-KB5 generator set for the INA Molve gas processing facility in Croatia. The package will be supplied through KONCAR – Power Plant and Electric Traction Engineering Inc, which is the project's main contractor on behalf of INA-Naftaplin, the Croatia national oil and gas company.

Nov 2005 – Centrax was awarded an order for a 5.2-MWe CX501-KB7 generator set for installation at the Tunisian paper mill, Sotipapier. The gas turbine package will supply electricity and heat, the latter to be used to generate steam for use in the production of paper.

Centrax Ltd N/A Sep 2005 – Centrax was awarded a follow-on order for a 5.2-MWe CX501-KB7 generator set for installation at Spanish ceramics giant Taulell SA's plant near Castellon, Spain.

Timetable Month Year Major Development

1952 Start of development of Model 501/T56 aviation turboprop engine 1956 First aero-engine application acquired 1962 First industrial 501-K installed 1971 First marine application garnered on DD-963 class Mid- 1987 Initial AG9130s sent to Bath Iron Works Aug 1990 First sea trial of AG9130-equipped Arleigh Burke class destroyer Late 1990 Testing of CWS external combustor completed Jun 1991 Allison announces work on Model 501-KB7 Late 1991 Effusion-cooled combustion liners made available Late 1991 Pilotless dual-fuel nozzles become available 1992 Model 501-KB7 becomes available May 1993 Catalytica and Allison announce LoI for joint program on ultra-low emission catalytic

combustion system 1994 Model 501-KB3 and Model 501-KB4 become available 1998 Model 601-K machines shipped 1998 ATS low-emissions project with DoE, Gas Research Institute begins 1998 Turbomeca becomes supplier of 501-K gensets 1999 ATS component tests begun

August 2009


Rolls-Royce 501-K

©2009 August 2009

Month Year Major Development Nov 2005 Centrax gets first order from Tunisia 2006 Launch of first ROK AG9140-equipped KDX-3 destroyer Thru 2018 Continued production/availability of 501-K I&M series

Worldwide Distribution/Inventories At the start of 2009, more than 2,137 Rolls-Royce 501-K series gas turbine engines had been built and installed in 43 nations and territories worldwide. Major customer nations are China (32 machines, including Hong Kong), Canada (35), Egypt (56), France (72), India (91), Iran (65), Japan (51), Mexico (56), U.K. (59), U.S. (944), and Venezuela (60).

Forecast Rationale The Rolls-Royce 501-K machine series continues to garner orders despite brisk competition from machines from Solar, Kawasaki, GE Oil & Gas, and Siemens AG (the latter referring to the former Alstom line of machines whose power output is less than 50 MW).

Rolls-Royce has been working actively in emissions reduction, focusing on lean premix and catalytic combustion systems (Rolls and Solar have even worked together on assessing the durability of various catalysts). The ongoing effort has made the 501 K very viable and competitive from an emissions perspective. In addition, Rolls-Royce continues to update the gas turbine with the most current technology, including adopting aeroengine technology.

The 501-K continues to be sold for electrical generation duty, in particular by Centrax, the U.K.-based firm that remains in the forefront for booking the greatest number of orders for the engine model. Even with Centrax active, a few machines have been installed recently in Japan by IHI. We have not yet heard of any orders booked by Turbomeca.

In the mechanical drive arena, the 501-K should continue to sell well, taking advantage of the large base of installed Allison/Rolls-Royce machines worldwide.

With the use of Rolls-Royce's long-term service agreements, the customer of 501-Ks (and of all of

Rolls-Royce's product line) secures Rolls-Royce as the service and maintenance provider in multiyear contracts, ensuring continuity and reducing costs over the long term.

Overall, Rolls Royce is projected to produce 471 of the 501-K series gas turbines in the 10-year period 2009-2018, largely for generation/cogeneration duty. A total of 114 501-K units are forecast for duty as mechanical drivers, including the 501-KC7.

Our forecast contains many 501-KH5 steam-injected models. We feel that the time is ripe for those models.

Our forecast does not break out the mechanical drive 501-KC7 from that of the 501-KC5. We have not seen sufficient orders for that 5,500-bhp machine (as of the date of this report) to warrant a separate line item in the Ten-Year Outlook chart, below.

Our forecast does not include regular series production of the 501-K for marine propulsion. Orders for the gas turbine for that application will most likely be twos and threes at infrequent intervals in the decade.

The AG9140s for the ROK's 7,000-ton KDX-3 class destroyers are contained in the chart, below, under "Industrial Power Generation."

Page 14 Industrial & Marine Turbine Forecast – Gas & Steam Turbines

Rolls-Royce 501-K

Ten-Year Outlook

ESTIMATED CALENDAR YEAR UNIT PRODUCTION

Designation or Program High Confidence Good Confidence Speculative

Thru 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 Total

Rolls-Royce Energy

501 (RR) -K B5 <> MW 3.0 to <10.0 <> Industrial Power Generation 1,316 10 10 10 10 10 11 11 11 10 10 103

501 (RR) -K B7 <> MW 3.0 to <10.0 <> Industrial Power Generation 236 20 20 20 22 22 22 20 20 20 20 206

501 (RR) -K C5 <> MW 3.0 to <10.0 <> Industrial Power Generation 31 3 0 4 5 6 6 6 6 6 6 48

501 (RR) -K C5 <> SHP 3,000 to <10,000 <> Mechanical Drive (Pumps & Compressors) 554 10 12 12 12 10 10 12 12 12 12 114

Subtotal 2,137 43 42 46 49 48 49 49 49 48 48 471

Total 2,137 43 42 46 49 48 49 49 49 48 48 471

August 2009

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